High energy, light weight, lead-acid storage battery

Abstract

Light weight, low resistance electrode plates for lead-acid batteries are formed from a highly conductive non-lead substrate such as aluminum or copper, coated with a continuous layer of a corrosive resistant conductive materials, such as lead, applied from a fused salt bath.

We claim:  
     
       1. Lightweight, low resistance electrode plates for lead-acid batteries comprising: 
       a) a highly conductive non-lead substrate having a specific gravity no greater than 70% that of lead;  
       b) a continuous outer layer of a conductive material that is corrosive resistant to the electrolyte acids of the battery;  
       c) a striking layer between the substrate and the outer layer of conductive material selected from the group consisting of copper, nickel, titanium, zinc, tin and gold which serves to bond the lead to the substrate.  
       d) the outer continuous layer having a thickness in the range of 0.0001 to 0.0005 inches and being applied from a fused salt bath.  
     
     
       2. The electrode plate according to  claim 1  wherein said substrates are selected from the group of materials consisting of aluminum, magnesium, copper, and alloys thereof. 
     
     
       3. A lead-acid battery of the type having a plurality of alternating electrodes housed in a compartment containing electrolyte, wherein at least the current collecting electrodes comprise: 
       a) a highly conductive non-lead substrate selected from the group consisting of aluminum, aluminum alloys, aluminum/magnesium alloy, copper, copper alloys, graphite, carbon fibers, and conductive plastics;  
       b) a striking layer of conductive material selected from the group consisting of copper, nickel, titanium, zinc, silver, tin and gold which serves to bond the lead to the substrate;  
       c) an outer continuous layer of a corrosive resistant conductive material to electrolytic acids selected from the group consisting of lead, lead alloys, lead/tin alloys.  
       d) said continuous layer being applied from a fused salt bath formed of the molten salts selected from the group consisting of 50% sodium chloride/50% potassium chloride; 50% lead chloride/50% lead nitrate; and 50% potassium nitrate/50% sodium nitrate.  
     
     
       4. The lead-acid battery according to  claim 3  wherein said substrates are selected from the group of materials consisting of aluminum, magnesium, copper, and alloys thereof. 
     
     
       5. A method for claiming lightweight, low resistance electrode plates for lead-acid batteries comprising the steps of: 
       a) cleaning and preparing substrates formed of a conductive, non-lead material having a specific gravity no greater than 70% that of lead;  
       b) applying a striking layer of conductive material selected from the group consisting of copper, nickel, titanium, zinc, silver, tin and gold which serves to bond the lead to the substrate;  
       c) preparing a molten salt solution of at least a lead salt;  
       d) immersing the conductive, non-lead substrate into the molten lead salt for a period of time to coat the substrate with a lead coating of a desired thickness.  
     
     
       6. The method according to  claim 5  wherein said substrates are selected from the group of materials consisting of aluminum, magnesium, copper, and alloys thereof. 
     
     
       7. The method according to  claim 5  wherein the molten salt bath is formed of lead chloride. 
     
     
       8. The method according to  claim 5  wherein the molten salt bath is formed of lead chloride, lithium chloride, and potassium chloride with the lead chloride forming at least 80% of the bath. 
     
     
       9. The method according to  claim 5  wherein the bath is formed of lead chloride, and a lead/tin alloy. 
     
     
       10. The method according to  claim 5  wherein the molten salt bath includes lead chloride along with potassium chloride and sodium chloride, with the lead chloride comprising about 90% of the bath. 
     
     
       11. The method according to  claim 5  wherein the molten salt bath is selected from the group consisting of potassium nitrate, sodium nitrate, lead nitrate, and combinations thereof.